Hidden rail fastener connection system

ABSTRACT

A hidden rail fastener connection system utilizes open-ended top and bottom rail supports, each support having a bottom floor and upstanding side walls. An open-ended channel extends the length of each side wall and two or more open-ended channels extend the length of each bottom floor. Specially designed brackets are secured to the ends of the rail supports. The brackets have a set of openings aligned with the ends of the channels for the insertion of fasteners through the openings and into the channels and another set of openings for the insertion of fasteners into the vertical structures to which the rail and baluster system is to be attached. Top and bottom rail members are provided to enclose the rail supports and cover all fasteners.

BACKGROUND OF THE INVENTION

Railing systems for stairways, decks, porches, and other structures which employ guardrail type assistance and protection, usually consist of a number of vertical support newels or columns, inter-connected by handrails, from which balusters extend. These components are commonly connected to each other with nails, screws, rivets, or nuts and bolts. Unfortunately, such fasteners provide only a relatively small contact surface area between the components. This results in a less than secure and permanent connection, one which will often work loose and cause instability in sections of the railing system. Even after attachment, such fasteners remain exposed and extend out from the railing components. This poses a safety risk to those who use the railing system or pass by it. Aesthetically, exposed fasteners are unsightly and severely detract from the appearance of the overall railing system.

Several rail connection systems are described in the prior art which seek to address the problem of exposed fasteners. For instance, the rail connection system disclosed in U.S. Pat. No. 6,874,766 attempts to hide its fasteners, but in so doing sacrifices the integrity of the railing connection. The system uses simple end connectors which are positioned on the bottom of a supporting insert. Such an attachment results in limited lateral strength and a generally weak connection between components.

SUMMARY OF THE INVENTION

It is thus the object of the present invention to provide a hidden rail fastener connection system which overcomes the limitations and disadvantages of and represents a significant improvement over prior systems.

It is an object of the present invention to provide a hidden rail fastener connection system which provides a strong, stable and permanent connection between all rail and baluster system components and the vertical structures to which they are attached.

It is another object of the present invention to provide a hidden rail fastener connection system which uses relatively few attachment elements to form the fastening connection between rail and baluster system components.

It is still another object of the present invention to provide a hidden rail fastener connection system which connects and secures rail system components without exposed fasteners which may present a safety risk.

It is a further object of the present invention to provide a hidden rail fastener connection system which permanently connects and secures rail system components without exposed fasteners, thus greatly enhance the appearance of the system.

It is yet another object of the present invention to provide a hidden rail fastener connection system which is easy and simple to assemble.

These and other objects are accomplished by the present invention, a hidden rail fastener connection system utilizing open-ended top and bottom rail supports, each support having a bottom floor and upstanding side walls. An open-ended channel extends the length of each side wall and two or more open-ended channels extend the length of each bottom floor. Specially designed brackets are secured to the ends of the rail supports. The brackets have a set of openings aligned with the ends of the channels for the insertion of fasteners through the openings and into the channels and another set of openings for the insertion of fasteners into the vertical structures to which the rail and baluster system is to be attached. Top and bottom rail members are provided to enclose the rail supports and cover all fasteners.

Novel features which are considered as characteristic of the invention are set forth in particular in the appended claims. The invention, itself, however, both as to its design, construction and use, together with additional features and advantages thereof, are best understood upon review of the following detailed description with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view of the components of the system of the present invention.

FIG. 2 is an exploded view of the top rail components of the system of the present invention.

FIG. 3 is an end view of the top rail components of the system of the present invention as the top rail would be secured to a newel post.

FIG. 4 is a perspective view of a support rail component of the present invention secured between newel posts.

FIG. 5 is a partial section view of a rail support of the system of the present invention as installed between newel posts.

FIG. 6 is an exploded view of an alternate embodiment of the top rail components of the system of the present invention.

FIG. 7 is an elevation view of the rail support shown in FIG. 6 located for installation between vertical wall structures.

DETAILED DESCRIPTION OF THE INVENTION

The hidden fastener rail connection system of the present invention is provided to secure both the top and bottom rails of a railing/baluster system. Both top rail support 2 and bottom rail support 4 comprise an elongated, lightweight extruded member, preferably, although not limited to, aluminum.

Using top rail support 2 as an example, as seen in FIG. 2, the rail support has bottom floor 6 and upstanding sidewalls 8 and 10. Open ended channels 12 and 14 extend along the full length of bottom floor 6 and open ended channels 16 and 18 extend along the full length of side walls 8 and 10 respectively. Substantially flat bracket members 20 comprise first set of openings 22, 24, 26 and 28. Bracket members 20 are configured to be placed adjacent to and cover both ends of top rail support 2, such that openings 22, 24, 26, and 28 are aligned over the ends of open-ended channels 12, 14, 16, and 18 respectively. With bracket members 20 so positioned, screw channel fasteners 32, 34, 36, and 38 are inserted into openings 22, 24, 26, and 28 in both bracket members and then screwed into channels 12, 14, 16, and 18, to secure the bracket members to rail support 2.

Bracket member 20 also comprises openings 23, 25 and 27 to receive rail fasteners 33, 35 and 37 which are configured to be oriented 180° in relation to the channel fasteners. (See FIG. 3). The rail fasteners secure the railing/baluster system to the newels, columns or walls to which the system is to be attached.

Top rail support 2 is supported by and nested within baluster cap 40, which itself has lateral channels 42 and 44. Top rail 50 has elongated tab sections 46 and 48. Top rail 50 is configured to cover both top rail support 2 and cap 40. Tab sections 46 and 48 are configured to snap into lateral channels 42 and 44, to complete the top rail portion of the rail/baluster system.

In like fashion, bottom rail support 4 is enclosed within bottom rail 60. Bottom rail 60 is configured to straddle, cover, and attach to bottom rail support 4.

Installation of the railing/baluster system, by use of the connection system of the present invention, first comprises securing balusters 70 to cap 40 and bottom rail 60 via screws or equivalent fasteners. Top rail support 2 and bottom rail support 4 are then cut to the requisite length. Bracket members 20 are attached to the ends of top rail support 2 and bottom rail support 4 by inserting and screwing channel fasteners 32, 34, 36, and 38 through bracket openings 22, 24, 26, and 28 and into channels 12, 14, 16 and 18 of the rail supports.

Rail fasteners 31, 33, and 35 are then inserted into openings 23, 25 and 27 of bracket members 20 and screwed into newel posts or columns 62 and 64 or, optionally between two walls or a wall and newel or column, to secure bottom rail support 4 therebetween. Bottom rail 60, with attached balusters 70 and cap 40, is positioned and secured over bottom rail support 4, thus covering and hiding all fasteners securing the lower portion of the railing/baluster system.

Top rail support 2 is placed into nested position within cap 40. Once again, rail fasteners 31, 33, and 35 are inserted into openings 23, 25, and 27 of bracket members 20, this time to secure top rail support 2 between vertical supporting structures, e.g. newels, columns, or walls. Finally, top rail 50 is positioned and secured over top rail support 2 and secured to cap 40, thus covering and hiding all fasteners securing the upper portion of the railing/baluster system.

The rail connection system of the present invention can also be utilized to connect stairway railing/baluster systems. As seen in FIGS. 6 and 7 showing the top rail support system, upper end 74 of rail support 72 is cut at a diagonal, so as to be parallel to column, newel or similar vertical structure 200. Bracket member 80 is similar to bracket member 20, except that when placed adjacent to upper end 74 of rail support 72, it is positioned at a non-right angle to the rail support. Openings 82, 84, 86, and 88 of bracket member 80 are configured such that screw channel fasteners 32, 34, 36 and 38 are easily and more readily insertable into channels 12, 14, 16 and 18 of the rail support, for securing the bracket member to the rail support.

Stair rail bracket member 90 comprises bracket attachment arm 92 and bracket support arm 91 extending perpendicular to the attachment arm. Bracket attachment arm 92 of bracket 90 is positioned perpendicular and adjacent to lower end 76 of rail support 72 and fasteners 36 and 38 are inserted through openings 96 and 98 and then into channels 16 and 18 to secure bracket 90 to rail support 72. Rail support 72 is then placed adjacent to column, newel or vertical structure 202, such that bracket support arm 91 is against the structure. (FIG. 7). Fasteners 33, 35, and 37 are next inserted into openings 93, 95, and 97, as previously discussed with regard to FIG. 3, to secure lower end 76 to vertical structure 202. Rail 100 is then snapped onto cap 94, nested below rail support 72, to complete the connection.

Certain novel features and components of this invention are disclosed in detail in order to make the invention clear in at least one form thereof. However, it is to be clearly understood that the invention as disclosed is not necessarily limited to the exact form and details as disclosed, since it is apparent that various modifications and changes may be made without departing from the spirit of the invention. 

1. A hidden fastener rail connection system for attaching rail members between vertical structures, said system comprising: elongated top and bottom rail supports each having first and second open ends and each comprising a bottom floor, the bottom floors having a plurality of open-ended channels extending the length of the rail supports, and upstanding side walls, the side walls each having at least one open-ended channel extending the length of the rail supports; bracket means for placement over the ends of the rail supports, said bracket means comprising a first set of opening means for the insertion of fasteners through the bracket means and into the channels of the bottom floors and the side walls of the rail supports, said bracket means further comprising a second set of opening means for the insertion of fasteners through the bracket means and into vertical structures; cap means for supporting the top rail support; a top rail for enclosing the cap means and top rail support and for covering the fasteners inserted through the bracket means; and a bottom rail for enclosing the bottom rail support and for covering the fasteners inserted through the bracket means.
 2. The rail connection system as in claim 1 further comprising balusters secured between the cap means and the bottom rail.
 3. The rail connection system as in claim 1 wherein the bottom floors of the rail supports comprise two open-ended channels and each of the side walls comprise one open-ended channel.
 4. The rail connection system as in claim 1 wherein the bracket means comprises a first bracket member located adjacent to the first open end of each rail support and a second bracket member located adjacent to the second open end of each rail support.
 5. The rail connection system as in claim 3 wherein the bracket means comprises a first bracket member located adjacent to the first open end of each rail support and a second bracket member located adjacent to the second open end of each rail support, each bracket member having a first set of opening means, said first set of opening means comprising four openings for the insertion of fasteners through the bracket members and into the two open-ended channels of each of the bottom floors and the one open-ended channel of each of the side walls.
 6. The rail connection system as in claim 5 wherein each bracket member has a second set of opening means, said second set of opening means comprising two openings for the insertion of fasteners through the bracket members and into vertical structures.
 7. The rail connection system as in claim 4 wherein the first and second bracket members are positioned substantially perpendicular to the ends of the top and bottom rail supports when the fasteners are inserted through the bracket members into the rail supports.
 8. The rail connection system as in claim 4 wherein the first bracket members are positioned at a non-right angle to the ends of the rail supports when the fasteners are inserted through the first bracket members into the channels of the rail supports, and the second bracket members are positioned substantially perpendicular to the ends of the rail supports when the fasteners extend through the second bracket members.
 9. The rail connection system as in claim 8 wherein the second bracket member comprises a bracket attachment arm and a bracket support arm extending perpendicularly from said bracket attachment arm.
 10. The rail connection system as in claim 1 wherein the fasteners through the first set of opening means are oriented 180° direction in relation to the fasteners through the second set of opening means. 